Prefabricated portable flat pack building

ABSTRACT

A prefabricated portable building that meets flat pack pallet standards of the North Atlantic Trade Organization (NATO) is provided. The prefabricated building, includes 2 end units, wherein each end unit includes an outer wall, an inner wall, a roof, and a floor, wherein the outer wall and the floor converge to form an edge having an angle of less than 90 degrees, and wherein the inner wall and the floor converge to form an angle of about 90 degrees.

RELATED APPLICATION

[0001] The present application is related to U.S. Patent Application No.______, entitled “System and Method for Assembling PrefabricatedPortable Flat Pack Building”, by inventor David M. MacWatt, filed on thesame date as the present application, having Attorney Docket No.358031.00200, which is hereby incorporated by reference in its entirety.

COPYRIGHT NOTICE

[0002] A portion of the disclosure of this patent document containsmaterial which is subject to copyright protection. The copyright ownerhas no objection to the facsimile reproduction by anyone of the patentdocument or the patent disclosure, as it appears in the Patent andTrademark Office patent file or records, but otherwise reserves allcopyright rights whatsoever.

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] The present invention generally relates to portable buildingsand, more particularly, to prefabricated portable buildings that meetdesignated standards for flat pack transportation.

[0005] 2. Discussion of Background

[0006] People typically use prefabricated portable buildings foremergency situations. For example, the military may be in a situationwhere it needs to construct a hospital in a matter of hours. A permanentbuilding structure would be impractical. Consider a situation wherehospital facilities are needed-in a desert of the Middle East. Abuilding most suitable for military purposes would likely be some typeof prefabricated portable building that can be quickly erected with allthe necessary hospital facilities.

[0007] Manufacturers prefabricate portable buildings in a controlledfactory environment and ship the building pieces to the designated sitefor assembly. Users install these portable buildings at the designatedsite for temporary, as well as permanent, applications.

[0008] The industry has its beginnings in the post World War II era,when the huge demand for housing for returning GI's overwhelmed theconstruction industry's ability to deliver. The U.S. developedprefabricated portable housing as a solution to this demand. Othercountries with severe commercial building needs following the war, alsodeveloped simplistic modular construction techniques. In the followingdecades, technological advances have increased the quality of thoseinitial efforts, as well as opened the door to new applications ofmodular construction.

[0009] Today, people use prefabricated construction in almost everyindustry and walk of life, including construction offices, educationalfacilities, medical facilities, industrial uses, prison and correctionalhousing and administration, branch financial offices, real estateoffices, government buildings, and general commercial offices.

SUMMARY OF THE INVENTION

[0010] When users disassemble a prefabricated building, they often needto place the pieces of the building into a “flat-pack” pallet. The flatpack form of a portable building is basically the walls, floors, roofs,and fittings of the building broken down into their smallest portablepackage. A flat-pack pallet sets limits on the building'sspecifications, such as size, weight and strength. Moreover, the NorthAtlantic Trade Organization (NATO) has their own guidelines on thespecifications of a standard flat-pack pallet. Thus, engineers are facedwith the challenge of designing a structure that is not only portable,but is also compliant with NATO guidelines and any other guidelines.

[0011] It has been recognized that what is needed is a prefabricatedflat pack building that meets flat pack pallet standards of the NorthAtlantic Trade Organization (NATO). Broadly speaking, the presentinvention fills this need by providing a fast response building, whichis a building designed, among other things, to meet the flat packstandards of NATO. It should be appreciated that the present inventioncan be implemented in numerous ways, including as a process, anapparatus, a system, a device or a method. Several inventive embodimentsof the present invention are described below.

[0012] In one embodiment, a prefabricated portable flat pack buildingthat is a single unit building is described. The prefabricated building,comprises 2 end units, wherein each end unit includes an outer wall, aninner wall, a roof, and a floor, wherein the outer wall and the floorconverge to form an edge having an angle of less than 90 degrees, andwherein the inner wall and the floor converge to form an angle of about90 degrees.

[0013] In another embodiment, a prefabricated portable flat packbuilding that is a multiple unit building is described. Theprefabricated building comprises 2 end units, wherein each end unitincludes an outer wall, an inner wall, a roof, and a floor, wherein theouter wall and the floor converge to form an edge having an angle ofless than 90 degrees, and wherein the inner wall and the floor convergeto form an angle of about 90 degrees; and one or more intermediateunits, wherein the one or more intermediate units share a same anglemeasurements of the 2 end units.

[0014] In still another embodiment, an end unit of a prefabricatedportable flat pack building is described. The end unit comprises anouter wall; an inner wall; a roof; and a floor, wherein the outer walland the floor converge to form an edge having an outer wall angle ofless than 90 degrees, and wherein the inner wall and the floor convergeto form an inner wall angle of about 90 degrees.

[0015] Prefabricated portable flat pack buildings have many advantages.A significant advantage of prefabricated construction is time savings.Manufacturers may build prefabricated flat pack buildings on acontrolled timetable in a factory environment. On the other hand,site-built buildings are subject to weather conditions, subcontractordeals, waits for permits, and labor shortages. Prefabricatedconstruction also provides cost savings due to standardization of theengineering process, bulk purchase of building materials and thecontrolled factory construction environment. Users of portable buildingsgain an additional advantage in the quality of construction. Astandardized construction method at the factory with skilled andknowledgeable labor means a building is not dependent on the vagariesand availability of the local labor market.

[0016] Another significant advantage of prefabricated portable flat packbuildings is economy of space. When disassembled in their flat packform, prefabricated portable flat pack buildings may be stored at anyappropriate location, including a warehouse, outdoors, or any locationthat may be substantially smaller than the building in its assembledform. A prefabricated portable flat pack building according to thepresent invention can be broken down into an economically small spacefor easy transport and storage.

[0017] The invention encompasses other embodiments of a system, amethod, and an apparatus, which are configured as set forth above andwith other features and alternatives.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The present invention will be readily understood by the followingdetailed description in conjunction with the accompanying drawings. Tofacilitate this description, like reference numerals designate likestructural elements.

[0019]FIG. 1A and FIG. 1B show perspective views of a single fastresponse building (FRB), in accordance with an embodiment of the presentinvention.

[0020]FIG. 2 shows a side view of the end unit, in accordance with anembodiment of the present invention.

[0021]FIG. 3 shows perspective views of segments of an FRB flat packedinto a pallet, in accordance with an embodiment of the presentinvention.

[0022]FIG. 4A and FIG. 4B show perspective views of a multiple unit FRB,in accordance with an embodiment of the present invention.

[0023]FIG. 5A and FIG. 5B show perspective views of a multiple unit FRBwith a joining corridor, in accordance with an embodiment of the presentinvention.

[0024]FIG. 6 through FIG. 52 combine to show an assembly process of amultiple unit FRB with a joining corridor, in accordance with embodimentof the present invention.

[0025]FIG. 53 shows examples of the clips and pins used to join thepanels of the FRB together, in accordance with an embodiment of thepresent invention.

[0026]FIG. 54 shows an example of a clip component that is wired to thewelded clip component with a wire, in accordance with an embodiment ofthe present invention.

[0027]FIG. 55 shows an example of a locking pin, in accordance with anembodiment of the present invention.

[0028]FIG. 56 shows an example of a foot-type pin, in accordance with anembodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] An invention for a prefabricated portable flat-pack building isdisclosed. Numerous specific details are set forth in order to provide athorough understanding of the present invention. It will be understood,however, to one skilled in the art, that the present invention may bepracticed without some or all of these specific details.

[0030] General Overview

[0031] Fast response buildings (FRB's) are prefabricated portablebuildings designed to be transported in flat-pack pallets. An FRB takesonly about 4 people fifteen minutes to construct into a rigid structurefor immediate use. No screws, no nuts, no special tools and no groundpreparation are needed. An FRB is fully insulated for use in extremeclimatic conditions. The FRB system is economical to transport by air,sea, road or rail.

[0032] FRB units are made from individual lightweight sections whichinterlock to form a rigid structure. Individual components make it easyto handle and maneuver, allowing each unit to be constructed in the mostdifficult locations. FRB can be situated virtually anywhere, includingforests, mountains, desert sand, snow, ice and most types of terrain.FRB units can be transported and positioned by helicopter, as flat packsystem or a complete constructed unit. FRB units are compatible with anyconventional cargo transportation system. Alternatively, each individualsections can be carried to site and constructed.

[0033] Relocating without dismantling is achieved by 3 speciallydesigned ski-bars located at the base of the unit. The base unitprovides for 2 couplings, which can be attached to a tow-bar by rope orchain allowing the building to slide and move in position. A vehiclesuch as a Land Rover is capable of achieving this sliding task onaverage ground conditions.

[0034] FRB flexible and unique modular units can be used to constructanything, from a single leisure home or storage unit, to a largeemergency hospital complex or emergency re-housing due to a disaster.Each unit can sleep up to 10 people. Principally designed for Emergencyaccommodation for Peace Keepers and Military requirements, an FRB'sapplications are endless.

[0035] Types of Fast Response Buildings

[0036]FIG. 1A and FIG. 1B show perspective views of a single FRB, inaccordance with an embodiment of the present invention. The singlebuilding comprises two end units 102, including an outer wall 106, aninner wall 108, and a roof 104, among other things.

[0037]FIG. 2 shows a side view of the end unit 102, in accordance withan embodiment of the present invention. The roof 104 and the base 110(or floor) have the same dimensions. However, the outer wall 106 and theinner wall 108 do not have the same dimensions. The height of the innerwall 108 is slightly greater than the height of the outer wall 106.Angle θ is set to be about 90 degrees. While angle φ is set to be lessthan 90 degrees, specifically between about 86 degrees and 88 degrees.Accordingly, the outer wall 106 leans at a slight angle inward.

[0038] Established rules of trigonometry set limitations on allowablemeasurements for angles ω and ρ. Angle ω is accordingly less than 90degrees, for example, between about 83 and 85 degrees. Angle ρ isaccordingly greater than 90 degrees, for example, between about 98 and100 degrees.

[0039] Important features of the FRB is the slight inward tilt of theouter wall 106, the height of the inner wall.108 being slightly greaterthan the height of the outer wall 106, and the equality in dimensions ofthe roof 104 and the base 110 (or floor). This combination createsunique building measurements that allow the FRB to be disassembledneatly into a standard NATO flat pack pallet.

[0040] It should be noted, however, that the present invention is notlimited to the specific measurements provided above. The specificmeasurements provided above are primarily for exemplary purposes to showthe inward lean of the outer wall 106.

[0041] Clips and Pins Assembly System

[0042]FIG. 53 shows examples of the clips 204 and pins 202 used to jointhe panels of the FRB together, in accordance with an embodiment of thepresent invention. These clips and pins are unique-to the system andreplace bolts, nuts and screws. In the example of FIG. 53, the clips arewelded and/or clipped to the respective panels and are extremelydifficult to damage or lose. In particular, the clips 204 and pins 202lock the whole FRB together in a manner that is robust yet retains adegree of flexibility. Assembly of the FRB using clips 204 and pins 202is less time consuming than assembly of a structure that usesconventional fixings, such as bolts, nuts and screws.

[0043] As shown in FIG. 53, the pins 202 are inserted where required inorder to prevent horizontal and vertical movement. As such, the pins 202are an integral part of the system. The pins 202 and clips 204 are usedthroughout the FRB structure to lock wall to wall, wall to gable, wallto roof, roof to gable, etc.

[0044]FIG. 54 shows an example of a clip component 302 that is wired tothe welded clip component 204 with a wire 304, in accordance with anembodiment of the present invention. The wired clip component 302 locksthe FRB superstructure in place.

[0045]FIG. 55 shows an example of a locking pin 402, in accordance withan embodiment of the present invention. This locking pin 402 with thelocking feature is used to secure the probes (which- connect the basesections together), the skids, the legs (when flat packed assembled),the veranda (or step) and the mast stabilizer to the FRB. The lockingpin 402 includes a washer 406 having a slot. To the fix the locking pin402, the locking pin 402 is placed in the base runner using the handle408 at the top of the locking pin 402. The locking pin 402 is maneuveredto allow the slot in the washer 406 to pass through the seg 404, whichis attached to the base runner. When the handle is released the lockingpin 402 turns and will not free itself. Note that the sizes anddiameters shown here are for explanatory purposes, and may vary.

[0046]FIG. 56 shows an example of a foot-type pin 502, in accordancewith an embodiment of the present invention. The foot-type pin isanother way of locking components (e.g., gable, base, wall, and roof) ofthe FRB into place. The foot-type pin 502 is maneuvered into theappropriate hole and slides into place. In this example, a wall is shownbeing locked to the base 110. Note that the sizes and diameters shownhere are for explanatory purposes, and may vary.

[0047]FIG. 3 shows perspective views of segments of an FRB flat packedinto a pallet, in accordance with an embodiment of the presentinvention. All of the component parts flat pack on to its own base 110(or floor). The flat pack segments may then stack upon each other.Accordingly, when flat packet, one half of the base 110 of the unitbecomes the pallet. The components of the FRB are placed on top of thathalf of the base 110. The remaining half of the base 110 is stacked ontop of the components with the leg sockets 602 of the top half of thebase 110 situated to be in line with the leg sockets 602 of the bottomhalf of the base 110. The legs 604 are then inserted. The resultingbox-like unit is locked together with the locking pins.

[0048]FIG. 4A and FIG. 4B show perspective views of a multiple unit FRB,in accordance with an embodiment of the present invention. The multipleunit building comprises 2 ends and the intermediate units 302 areinserted as required. FIG. 3 shows 4 intermediate units 302. However,the number of intermediate units 302 that can be inserted is, in theory,infinite. For example, an intermediate unit 302 may be about 2.25 m inlength. These intermediate units 302 may be added such that the lengthof the FRB is a multiple of 2.25 m. Note that the present invention isnot limited to these specific dimensions, and other appropriatedimensions for intermediate-units 302 may be used.

[0049]FIG. 5A and FIG. 5B show perspective views of a multiple unit FRBwith a joining corridor, in accordance with an embodiment of the presentinvention. The multiple unit building with a joining corridor comprises4 end units 102. The intermediate units 302 and corridors 402 areinserted as required. Note that segment walls, floors, and ceilings ofall the FRB units have the same dimensions and will flat pack onto aNATO pallet for easy portability.

[0050] Assembly Process of a Fast Response Building

[0051] The sequence FIG. 6 through FIG. 52 steps through an assemblyprocess of a multiple unit FRB with a joining corridor, in accordancewith embodiment of the present invention. The assembly process starts inFIG. 6 with a floor segment. The assembly finishes in FIG. 52 with afully assembled multiple unit FRB with a joining corridor. Intermediatefigures FIG. 6 through FIG. 51 sequentially step through the assembly ofthe multiple unit FRB.

[0052] Additional Features and Advantages of a Fast Response Building

[0053] A fast response building (FRB) may be equipped to suit anyenvironment. An FRB may be provided with added solar protection. An FRBmay be equipped with added insulation. An FRB can also have nuclearbiological and chemical (NBC) lining along its interior. An FRB may havemosquito or fly screens for doors and windows. An FRB may have maststabilizers for wind generators or aerials. An FRB may have rain watercollection and storage mechanisms. An FRB may have ballistic protection,applique armor, up to, but not limited to, about 7.62 standard NATOball. An FRB may have load spreader plates, to cater for dessert or wetground. An FRB may have a multi solid fuel stove for cooking andheating.

[0054] FRB's have many advantages. FRB units are easily deployable. Ascan be seen in the sequence FIG. 6 through FIG. 52, FRB units are easilyassembled on any type of terrain. Adjustable legs produce a levelplatform. FRB's can be erected quickly.

[0055] FRB's are mobile. FRB's are transported in flat pack pallets andcan be moved by air, sea, vehicle and on their own wheels. Nosignificant wear and tear occurs during transport and assembly of theFRB pallets and FRB infrastructure because their made of rugged steel.An FRB is designed to be stacked outside when not in use, and canwithstand harsh weather conditions while stored outside. An FRB can bemanufactured and repaired substantially anywhere, including countrieshaving only low tech facilities. Even if a particular locale does nothave the necessary facilities and parts to repair the FRB locally, theparticular locale can send out for spare parts without difficulty.Alternatively, parts of an FRB can be repaired locally by using ordinarymetallurgy techniques, for example, ordinary welding techniques. Thus,if a part of an FRB fails, the user of the FRB does not have to idlywait around for a new FRB to arrive.

[0056] FRB's have many applications. FRB's can be used individually,extended or interconnected to create field dressing stations, hospitals,workshops, classrooms and stores as well as accommodations.

[0057] In the foregoing specification, the invention has been describedwith reference to specific embodiments thereof. It will, however, beevident that various modifications and changes may be made theretowithout departing from the broader spirit and scope of the invention.The specification and drawings are, accordingly, to be regarded in anillustrative rather than a restrictive sense.

What is claimed is:
 1. A prefabricated portable flat pack building, theprefabricated flat pack building being a single unit building,comprising: 2 end units, wherein each end unit includes an outer wall,an inner wall, a roof, and a floor, wherein the outer wall and the floorconverge to form an edge having an angle of less than 90 degrees, andwherein the inner wall and the floor converge to form an angle of about90 degrees.
 2. The prefabricated flat pack building of claim 1, whereincomponent parts of the prefabricated flat pack building are configuredto be flat pack capable onto a base of the prefabricated flat packbuilding.
 3. The prefabricated flat pack building of claim 2, whereinthe component parts are stackable upon each other to fit into a palletstandardized by the North Atlantic Trade Organization (NATO).
 4. Theprefabricated portable flat pack building of claim 1, further comprisingat least one of: solar protection; insulation material; nuclearbiological and chemical (NBC) lining along interior surfaces; insectscreens for doors and windows; rain water collection and storagemechanisms; ballistic protection, applique armor, up to about 7.62standard NATO ball; load spread plates to cater for unstable ground; anda multiple solid fuel stove for cooking and heating.
 5. Theprefabricated flat pack building of claim 1, wherein the prefabricatedflat pack building includes component parts that are easily deployable.6. The prefabricated flat pack building of claim 1, wherein theprefabricated flat pack building includes component parts that aremobile.
 7. The prefabricated flat pack building of claim 1, wherein theprefabricated flat pack building is configured to be used in anenvironment in which a building structure is desirable.
 8. Theprefabricated flat pack building of claim 7, wherein the environment isat least one of: a dressing station; a hospital; a workshop; aclassroom; a field kitchen; a trauma center; an administration facility;a mobile command center; a store; and an accommodation.
 9. Aprefabricated portable flat pack building, the prefabricated flat packbuilding being a multiple unit building comprising: 2 end units, whereineach end unit includes an outer wall, an inner wall, a roof, and afloor, wherein the outer wall and the floor converge to form an edgehaving an angle of less than 90 degrees, and wherein the inner wall andthe floor converge to form an angle of about 90 degrees; and one or moreintermediate units, wherein the one or more intermediate units share asame angle measurements of the 2 end units.
 10. The prefabricatedportable flat pack building of claim 9, further comprising a joiningcorridor, wherein the joining corridor is situated between two rows ofthe multiple unit building, and wherein the joining corridor sharesinner walls with the two rows of the multiple unit building.
 11. An endunit of a prefabricated portable flat pack building, comprising: anouter wall; an inner wall; a roof; and a floor, wherein the outer walland the floor converge to form an edge having an outer wall angle ofless than 90 degrees, and wherein the inner wall and the floor convergeto form an inner wall angle of about 90 degrees.
 12. The end unit ofclaim 11, wherein the outer wall angle is between about 86 degrees and88 degrees.
 13. The end unit of claim 11, wherein the outer wall angleis a slight angle inward.
 14. The end unit of claim 11, wherein theouter wall and the roof converge to form an edge having a roof-outerwall angle of between about 98 degrees and 100 degrees, and wherein theinner wall and the roof converge to form an edge having a roof-innerwall angle of between about 83 degrees and 85 degrees.